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TRANSCRIPT
AUTOMATED FORMULATION &DATA MANAGEMENT
FOR NEW PRODUCTINNOVATION
MARK BAKER
24-04-2017
OUTLINE OF TALK• Unilever & why we are interested in Automated Formulation
• End to End Automated Formulation & Data Management
• Key Challenges
• The Geoff Robot
• The Materials Innovation Factory
ABOUT UNILEVER
“MAKECLEANLINESSCOMMONPLACE”
UNILEVER ISA GLOBAL COMPANY
EUROPE
● €13.6 BILLION TURNOVER
● 2.6% UNDERLYINGVOLUME GROWTH
● 26% OF GROUPTURNOVER
ASIA/AMET/RUB
● €22.4 BILLION TURNOVER
● 3.0% UNDERLYING VOLUME GROWTH
● 42% OF GROUP TURNOVER
THE AMERICAS
● €17.3 BILLION TURNOVER
● 0.4% UNDERLYINGVOLUME GROWTH
● 32% OF GROUPTURNOVER
2015 TURNOVER = €53.3BN
WE MAKE MANY OF THEWORLD’S FAVOURITEBRANDS
WHY WOULDUNILEVER USEAUTOMATION INR&D?
THE WORLD FACESNEW AND BIGGERCHALLENGES
MAKESUSTAINABLELIVINGCOMMONPLACE
A NEW WAY OFDOING BUSINESS
EQUAL OPPORTUNITY& SUSTAINABLELIVELIHOODS
SUSTAINABLY SOURCEDRAW MATERIALS
THE PLANET PROTECTEDFOR FUTURE GENERATIONS
ACCESS TO WATERSANITATION &HYGIENE FOR ALL
OUR VISIONTO DOUBLE THE SIZEOF OUR BUSINESS,WHILST REDUCINGOUR ENVIRONMENTALFOOTPRINT ANDINCREASING OUR POSITIVESOCIAL IMPACT
POSITIVESOCIALIMPACT
DOUBLE THEBUSINESS
REDUCEENVIRONMENTAL
FOOTPRINT
DRIVINGINNOVATION
BIGGER BETTER FASTERINNOVATIONTo meet the ambition of USLP, we must radically reformulate our entireHomecare and Personal Care portfolio by 2020, this is not achievable withtraditional bench science. Instead we use a mix of automation andcomputation to explore wider formulation spaces faster.
END TO END AUTOMATION& DATA MANAGEMENT
‘END TO END’ AUTOMATION & HIGH THROUGHPUT
backbone hydration density
Vis
cosi
tyP
as-
1
Port Sunlight / MIF/ Daresbury
Port Sunlight
UoL -Micro
Biorefinery
UoL - UMPF
Partners to Win
Co-development
withCommercial
suppliers
Automation and Data/Computation used across projectsto enable product discovery, understanding andinnovation which would be difficult or impossible withconventional methods.
FLOW
• Registration of Materials, Lots, Formulations(with processing) and Substrates
‘HIGH THROUGHPUT OPERATING SYSTEM’
EMS
• Experiment configuration with meta data captureHarmony/Overlord
• ‘Common Interface between instruments and EMS
Pipeline Pilot
• Experiment Validation, Analysis andReporting
DecideHuman
Intellect &Intelligent
DoE
Data Mining/Modelling
Interpret& Refine
HumanIntellect &Computer
Aided Analysis
AutomatedReporting
AutomatedAnalysis
DatabaseStorage
Catalogue Materials
RecordDetails
DatabaseStorage
ConfigureMeasurementsRecord Details
Database Storage
Stability
MeasureRun Experiment
Screening
CreateFormulation
sRecordDetails
DatabaseStorage
HTOS In Practice
MakeRun
ExperimentDatabaseStorage
KEY CHALLENGES
• Viscous liquids with entrapped air
• Bridging powders
• Powders
• Hot Liquids
• Suspensions
DIVERSE RAW MATERIAL PALLETTE
• StickyPowders
DIVERSE PRODUCT PORTFOLIO
… from Domestos to Dove Shampoo … Persil Laundry Liquid & ComfortFabric Conditioner
DIVERSE USER NEEDS
• Hot Processing
• pH Measurement& Goal seeking
• ThicknessMeasurement& Goal seeking
• Homogenisation
• Foam detection• PreciseDosingControl
• Temperature control
• Mixing LiquidProducts
GEOFFAUTOMATEDFORMULATIONROBOT
AUTOMATED FORMULATION – ‘GEOFF’ ROBOT
Powders
24 x 800 gBatches per run
4 xFormulation
Stations
Temp Control
Modularity andredundancy
pH adjustment Viscosityadjustment
FormulationPot Input &
Output
ViscousLiquids
HotLiquids
Suspensions Standardised softwarefor ingredients & process
Foamdetection
Clean Mixersin Place
Homogeniser
Configurablemixers
Gravimetricdispensing
Formulationin Final Pot
AUTOMATED FORMULATION – POWDERS
PowderModule
RemovablePowderHopper
Powder Boat
Hot Liquidand
SuspensionDispensing
ViscousDispensing Small
VolumePressure
Dispensing
AUTOMATED FORMULATION – LIQUIDS
Removal ofmodule
Capping and Decapping
AUTOMATED FORMULATION – GEOFF
MATERIALS INNOVATIONFACTORY
MATERIALS INNOVATION FACTORY
• A world’s leading centre for Computer Aided Materials Science, focusingon materials chemistry, soft solids and complex mixtures.
• 9 Dedicated Academics & 12 Technical support staff for the Open AccessArea (OAA)
• OAA operates on a credits system; credits available to 3rd parties as wellas Uni. Of Liverpool & Unilever to create a sustainable business model
• OAA contains leading edge automation comprising specifically purchasedkit & Unilever donated kit.
SPRING2017
Leading edgeautomation
InformaticsProviders
IntegrationSpecialists
PARTNERING
Partners
Materials Innovation Factory
Suppliers
THANK YOU – ANYQUESTIONS?
Thank you
Any Questions?AcknowledgementsLabman Automation LtdRegional Growth Fund & BISUnilever
Mark AutyMark NewmanAndy Mitchell